1Y Head Gasket or Oil Cooler?

[ORCoaster]

HO HO HO you have just been set up with the never-ending fix of the VW diesel engine.  Nothing stays static very long.  Always something to adjust, clean, or flat out fix.  And my friends ask what I do with all my "spare" time. 

[intramural]

Ha, thanks Dad. And to think he loved them so much because they were so reliable... "as long as you take care of 'em"

I do really appreciate you guys helping me do this though. It seems to run well and starts right up. I tried to take a video but I can't figure out how to upload it.

Hopefully the servo booster isn't totally ***ed.

[libbydiesel]

The belt looks fine on the crank sprocket.

What symptoms are you seeing that tell you the booster is leaking?

[intramural]

The belt looks fine on the crank sprocket.

What symptoms are you seeing that tell you the booster is leaking?

A hissing sound is coming directly from it. The noise lasts for 1-2 min after shutoff even it the engine is only ran for a few seconds. I haven't gotten much further than that.

Can I use some prestone or some other type of radiator cleaning fluid on my system to expedite the flushing process?

[intramural]

Yeah its for sure the servo booster/related to it. If i press the brake with the car off the hissing gets louder. I have plenty of pressure, is the only puzzling part.

There's a snake in my booster!

[ORCoaster]

The hissing is not the release of pressure but the loss of vacuum in the booster.  You can pull the line from the booster to the vac pump and test it with either pressure or vacuum and some soapy water.  Where you get bubbles under pressure you have a leak. 

If the booster itself is toast you can put a vacuum on it and listen for a leak there.  My guess is that the line or the fittings are bad.  They get more abuse than the booster.  But those parts are available so a new booster would help you keep your brake system maintained.  Fittings and check valves and hoses should be available at a local auto parts store. I don't think there is anything specific to VW that a universal part wouldn't work. 

Yeah, just keep it maintained.  LIKE WEEKLY for a while anyway.

[intramural]

Well, I am happy to report that the vacuum leak was in fact hose that just needed to be snugged up.

Looking at the belt on the IP sprocket is driving me nuts though. I might have to go in and redo the bracket. I just really don't want to take my chances with the belt. UGH.

The thought of taking the pump off again has me pretty irritated too though.

[intramural]

Okay Guys. I went back in and hogged out the holes on my mounting bracket.

After having the the pump on and off 5 times I feel OK about where I have it now.

IP Sprocket


Cam Sprocket


I looked down into the lower timing belt cover and the Crank sprocket looks like the injection pump one. What do y'all think?

Also, I took it out for a test drive at highway speeds, with a new longer probe egt. Libby you were 100% about my placement. With the new longer one I am seeing noticeably higher egt's. This is with my intercooler install which is putting in noticeably cooler charge air.

Thanks again for the help guys!

[libbydiesel]

Timing belt tracking looks good.  It all ran well on the highway?  Any untoward side effects or can we call it a win? 

[intramural]

Yeah, it ran great on the highway. I'm calling it a win for now, but I'm gonna keep my eye on everything for a little while.

I'm still flushing all the exhaust gas out of the coolant system too. But I think she's ready for the open road again.